System for forming building frame structures

ABSTRACT

A system for forming building framing structures comprising means for carrying elongated stud members along, and disposed transversely of, a predetermined path, the opposite ends of the stud members being disposed and adapted to receive elongated channel-shaped structural plate members seated thereon at the opposite ends of the stud members. Means for guiding the plate members in a manner to positively maintain a precise, predetermined spacing therebetween have been provided as the plate members are carried along the path and means for permanently securing the plate and stud members together during their passage along the path.

United States Patent Zaiss et al.

SYSTEM FOR FORMING BUILDING FRAME STRUCTURES [76] Inventors: Herman F. Zaiss, 1569 Jasper Drive,

Sunnyvale, Calif. 94087; Ross J. Hagel, 1984 Downing Court, Santa Clara, Calif. 9505] [22] Filed: Apr. 7, 1971 [21] Appl. No.: 131,917

[52] U.S. Cl. 29/200 P [51] Int. Cl B23p 19/00 [58] Field of Search 29/200 P, 200 R, -29/200 J, 200 B, 200 A, 208 R, 211 R [56] References Cited v. UNITED STATES PATENTS 3.367.0l0 2/1968 Lytle et al ..29/2()() J 3 6 52 22 o I I2 4 11 s. 4 B l 17 I4 E i O Primary Examiner-Thomas H. Eager Att0rneyFlehr, Hohbach, Test, Albritton & Herbert [57] ABSTRACT A system for forming building framing structures comprising means for carrying elongated stud members along, and disposed transversely of, a predetermined path, the opposite ends of the stud members being disposed and adapted to receive elongated channelshaped structural plate members seated thereon at the opposite ends of the stud members. Means for guiding the plate members in a manner to positively maintain a precise, predetermined spacing therebetween have been provided as the plate members are carried along the path and means for permanently securing the plate and stud members together during their passage along the path.

3 Claims, 10 Drawing Figures PATENIED M 3.747. 184

INVENTOR. HERMAN F. ZAISS ROSS J. HAGEL ATTORNEYS PMENVED TIH H sum 3 BF 3 INVENTOR. HERMAN F. ZAISS BY -T-FQOSS J. HAGEL flZy NM 124/ ATTORNEYS SYSTEM FOR FORMING BUILDING FRAME STRUCTURES BACKGROUND OF THE INVENTION This invention pertains to a system and method for forming building frame structures of a type employing studs and top and bottom plate members as well as the members which define window and door openings, for example, within the framing of a building wall. More particularly, this invention pertains to a system and method for mass producing such building frame structures and to novel building structures as produced thereby.

Heretofore, the framing of a building has typically been on a piece-by-piece basis at the job site. Typically, this type of construction tends to increase labor costs as compared to production line techniques.

As a solution to the above problem, a number of builders have turned to employing standard sized construction panels which are assembled as units at the job site. As disclosed herein, a system and method has been provided for production of the framing for buildings including the door and window openings, and also a novel building frame structure.

SUMMARY OF THE INVENTION AND OBJECTS In general, a system for forming building frame structures consisting generally of stud and plate members comprises means for carrying elongated stud members along, and disposed to extend transversely of, a predetermined assembly path. The opposite ends of the stud members are disposed and adapted to receive elongated channel-shaped structural plate members seated thereon at the opposite ends of the stud members so as to form the bottom and top construction plates of the wall framing. Means are provided for guiding the plate members to positively maintain a predetermined spacing therebetween particularly as where means, such as a welding machine, serves to permanently secure the plate and stud members together during passage of the assembly along its path.

Accordingly, it is a general object of the present invention to provide an improved system for mass production of the frame structures of construction walls as well as a generally improved frame structure per se.

Another object of the invention is to provide a system for the manufacture of construction wall framing as automatically as possible while retaining flexibility in design requirements.

A further object of the invention is to provide a system of manufacturing construction wall framing wherein the design of the framing may be laid out on a support carrier and then, by feeding the support carrier through the system, joints are automatically formed between stud and plate members as well as between the stud members and other cross members of the framing.

The foregoing and other objects will become more readily evident from the following detailed description of a preferred embodiment when considered in con junction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. I shows a diagrammatic perspective view of a system and apparatus for construction of a novel building wall framing structure.

FIG. 2 is an enlarged detail diagrammatic perspective view of a portion of the perforated support carrier platform shown in FIG. 1.

FIG. 3 shows an elevation section view taken along the line 3-3 of FIG. 1.

FIG. 4 is a diagrammatic plan view in the area desig nated 4 of FIG. 1 showing the disposition of retainers disposed on opposite sides of stud members carried by the support carrier platform in FIG. 1.

FIG. 5 is an enlarged elevation detail view, in section along the lines 55 of FIG. 1.

FIG. 6 shows in perspective an explanatory diagram of the operation and function of a portion of the apparatus shown in FIG. 1.

FIG. 7 is a perspective view of a portion of an improved building frame structure according to the invention.

FIG. 8 is an elevation section view taken along the line 8-8 of FIG. 7.

FIG. 9 shows a diagrammatic flow sheet for the assembly of an elongated building frame structure using prefabricated sections or units.

FIG. 10 is an enlarged perspective view of a floor portion formed according to the invention.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT A system 10 for forming building frame structures comprised of elongated hollow metal stud members 11 and transversely extending top and bottom construction plate members l2, 13 respectively, comprises a flat, perforated support platform 14 disposed upon and carried by a pair of I-beams 16 or other rigid frame members extending substantially the length of platform 14 and arranged to ride along a predetermined path disposed upon roller tracks 17. The platform 14 and I beams 16 are advanced along tracks 17 by any suitable means as schematically represented, for example, sim-' ply by the cable 18.

Means are provided for permitting any desired framing layout to be disposed upon the upper surface of platform 14 as, for example, by means of the multiple perforations 19 shown best in FIG. 2.

Means coacting with the perforations 19 for establishing the pattern or design to be established for the framing desired consist of plugs 21 formed at their lower end so as to enter into perforations 19 and at their upper end to provide a retaining body portion 21a whereby a number of stud members 11 can be readily releasably held in a pattern on the top surface of platform 14. Preferably, the opposite ends of stud members 11 extend to overhang the sides 14a of platform 14 whereby channel-shaped plate" members l2, 13 can be manually seated onto the stud end before platform 14 is moved along its predetermined path defined by tracks 17.

Means for guiding plate members 12, 13 so as to positively maintain a predetermined spacing therebetween consists of the rollers 22 closely bounding the sides of platform 14 for engaging plate members l2, 13. In this way, the maximum spacing between these two plate members will be determined.

System 10 further includes an aligning and joining station 23 formed as a bridge of angle iron members 24 for supporting a pair of heliarc welding machines 26, 27 arranged to feed welding material via a flexible cable 28, 29 respectively to a welding gun or head 30.

In addition to rollers 22 for maintaining the span of the framing being formed, additional rollers 31 are journalled in an adjustable guide bar 32 so as to press firmly against the backside of each of the plate members l2, 13 at a position where welding is to be performed. In addition, means for securely guiding and locating the two plate members 12, 13 relative to each other at the time of welding comprises the canted rollers 33 disposed to ride along the inside edge of plate members 12, 13 tending to urge the top edge ofplate members 12, 13 laterally outwardly against the restraint applied by rollers 31.

Similarly, an additional set of canted rollers 34 have been provided to ride beneath plate members 12, 13 and also to act against the bottom edge of members l2, 13 so as to force the bottom side of members 12, 13 toward restraining rollers 31.

All canted rollers 33, 34 are disposed in brackets 36 mounted to bridge 24 or, in the case of rollers 34, mounted to a supporting framework 35 disposed beneath bridge 24. Springs 40 within brackets 36 serve to pivot the axles 37 of each of the rollers 33, 34 in a direction so as to urge plate members 12, 13 laterally outwardly of the path of movement of platform 14 and against the restraining force of rollers 31. In addition, however, springs 40 permit the rollers 33, 34 to engage and pass over stud members 11.

Finally, the confronting sides 13a ofplate member 13 and similarly the confronting sides 12a ofplate member 12 are compressed tightly against the inserted opposite ends of stud members 11 by means of pressure rollers 38, 39 located respectively above and below plate members 12, 13. Pressure rollers 38 are journalled for rotation on a longitudinally extending support bar 41 carried between the two sides of bridge 24. Similarly, a support bar 42 carries pressure rollers 39.

Sensing means for operating each welding machine 26, 27 have been disposed in the form of the feeler elements 43 forming a portion of a microswitch 44 and disposed to operate its associated welding machine whenever feeler element 43 has been urged upwardly from its normally downwardly extending position. Accordingly, feeler element 43 extends downwardly into the path of the transversely extending elements disposed upon platform 14. Thus, as each of these particular transversely extending members, such as the stud members 11, pass beneath a feeler element 43, the welding machine associated therewith will be activated and a weld applied at the juncture defined between the upper edge of sides 12a, 13a and stud member 11. Similarly, as feeler element 43 is permitted to drop downwardly to its normal position, its microswitch 44 will open and serve to de-activate its associated welding machine.

It will be readily evident that the welding heads or guns 30 are permitted some freedom of location by means of the flexible cable connections 45 and 29 coupled thereto and, accordingly, each of the guns 30 is mounted upon a support bar 46 by means of a suitable clamp or bracket as shown. In this manner, limited positioning of the tip of guns 30 can be accommodated without requiring the movement of welding machines 26, 27 (or the lower welding machines 51) from their positions as shown. However, should it be necessary to make substantially large changes in position of the guns, this can be done by locating the welding machine 26 or 27 on the adjustable support bar 47 which is disposed to be moved variously along slots 48.

Inasmuch as it is generally considered desirable to apply a weld to both the top and the bottom seams defined between the sides l2a, 13a and the side faces of studs 11, additional welding guns 49 and machines 51 can be stationed beneath the path of the outer ends of stud members 11 for this purpose. Guns 49, as noted above, may be mounted upon support bar 42 and operated by means of one of the feeler elements common to guns 30 located above.

In order to apply a welded seam to the underneath portions of the framing carried on platform 14, in the regions of the parts defining windows and doors and other openings in the framing whereby they do not extend beyond the side edge of platform 14, openings may be formed to extend through platform 14 whereby welding equipment located beneath platform 14 and in the path of such openings can be activated to apply a weld in the manner described above.

As disclosed herein, for example, however, prefabricated framing sections 52 (FIG. 9) have been prepared and employed whereby only the overhanging ends of stud members 11 are required to be attached to plates 12, 13.

It will also be readily evident that the degree to which platform 14 is required to be drawn along its predetermined path may be significantly reduced by providing additional bridge assemblies 24 supporting welding machines and aligning rollers, as described above, variously along the length of platform 14. In this manner, the overall movement of platform 14 along its predetermined path can be substantially minimized.

In operation, the system described above requires that platform 14 first be prepared with plugs 21 at those locations serving to define the desired positions of stud members 11 and other structural components. Prefabricated units, such as 52, may be employed to provide door framing and window framing at appropriate locations on platform 14. Platform 14 is initially disposed well to the right of the position shown in FIG. 1 and, after having been properly prepared with the transversely extending structural members, longitudinally extending channel-shaped structural members are disposed upon the ends of the stud members so as to be firmly seated thereon.

At this point, it is to be observed and noted that a clearance 53 (FIG. 8) is maintained at least at one end of the stud members so that the two plate members 12, 13 may be perfectly aligned in accordance with the positioning action of rollers 22, 31, 33 and 34 (FIG. 6).

Next, platform 14 is drawn by means of cable 18 and motive means (not shown) of suitable style along its predetermined path relative to bridge 24 whereby, as each stud engages and moves a feeler element 43, an associated welding machine (or machines) will be activated and a secure longitudinally extending weld applied to the seam defined between the edges of sides 12a, 13a of plates 12, 13 and the side faces of the metal stud members 11.

With reference to FIGS. 7 and 8, wall framing as forming a corner has been shown wherein elongated hollow metal stud members 11 of substantially common length engage construction plate members 13 whereby the ends of the stud members 11 are disposed into the channel portion of the construction plate members 13 and the inserted ends are permanently secured to sides 13a by means of a line of weld 54. The bottom ends of stud members 11 are spaced clear of web 56 of the bottom plate members 13 whereby the top plate members can, as above described, be aligned in spaced precision parallel relation with respect to plate member 13.

Finally, the web portion of stud members 11 and plate members l2, 13 are formed with relatively large circular openings 57 for passing flexible conduit therethrough, the sharp edge of the openings being covered by means of a flexible elongated plastic protective element or grommet 58 formed with a U-shaped channellike cross-section for engaging the opposite faces of the web portions of the above members. In order to permit grommets 58 to be formed easily into a compressed or reduced circular configuration for insertion, a number of radial slits 59 have been formed in the flange por tions of the grommet element 58.

Finally, as represented in FIG. 10, a welded floor or ceiling structure has been provided taking advantage of the above system and comprising elongated parallel steel side members 61 (only one of which is shown) formed along the top and bottom edges with an inwardly turned lip 61a, 61b so as to strengthen members 61.

Joists 62 extend between the two parallel side members 61 and are attached thereto by a line of weld 63 laid between lip 61a and the top ofjoist 62. The length of the weld joint 63 has been extended to increase the strength of attachment by folding a portion 64 of the web of joist 62 and lying flush with lips 61a, 61b. Such a fold 64 also serves to strengthen joists 62 whereas additional rigidity can be obtained by pressing an elongated rib 66 into the web of joists 62.

The ends of side members 61 are joined by means of end joists 68 having upper and lower rolled lips 68a, 68b applied for strength. At the corner formed between member 61 and end joist 68, lips 68a, 6817 are notched to form a seam 69 aligned with seam 63.

As above described, access openings 67 are provided for passing cable and conduit, and it is to be understood that suitable anti-friction elements, such as 58, will be employed upon the bounding edge of such openings 67.

As shown in FIG. 9, and using pre-fabricated framing sections, such as 52, the framing for the walls ofa structure can be prepared by first locating sections 52 properly upon platform 14 at positions defined by plugs 21. The ends of the stud members included in sections 52 along one edge of platform 14 are then capped by bottom plate member 13. Thereafter, additional required stud members 11 are seated into base member 13 and thereafter the top plate member 12 is seated onto the upper ends of stud members 11. Finally, platform 14 is drawn relative to welding guns aligned with those portions desired to be joined.

We claim:

1. A system for forming stud and plate building frame structures comprising means carrying elongated stud members along a predetermined path while said stud members remain disposed to extend transversely of said path, the opposite ends of said stud members being disposed and adapted to receive elongated channelshaped structural plate members seated thereon at said opposite ends of said stud members, means adjacent said path for guiding said plate members when seated on the ends of said stud members, the last named means serving to positively maintain a predetermined spacing between said plate members, and means for permanently securing said plate and stud members together during passage thereof along said path.

2. A system for forming a building wall structure comprising an elongated support carrier, means coacting with said carrier defining the locations for, and serving to releasably hold, framing members secured to said carrier for forming portions of said wall structure, means supporting said carrier for movement along a predetermined path, means bounding said path and serving to closely define the span thereof, the last named means engaging said wall structure during movement thereof along said path to positively maintain the width thereof, and means disposed adjacent said framing members moving along said path for interconnecting said framing members during movement of said carrier along said path.

3. A system for forming a building wall structure comprising an elongated support carrier, means coacting with said carrier defining the locations for, and serving to releasably hold, framing members secured to said carrier for forming portions of said wall structure, means bounding said carrier and engaging said wall structure to positively maintain the span thereof, means adjacent said framing members when moving along said path for interconnecting framing members, and means for operating the last named means in response to relative movement between said carrier and said last-named means. 

1. A system for forming stud and plate building frame structures comprising means carrying elongated stud members along a predetermined path while said stud members remain disposed to extend transversely of said path, the opposite ends of said stud members being disposed and adapted to receive elongated channelshaped structural plate members seated thereon at said opposite ends of said stud members, means adjacent said path for guiding said plate members when seated on the ends of said stud members, the last named means serving to positively maintain a predetermined spacing between said plate members, and means for permanently securing said plate and stud members together during passage thereof along said path.
 2. A system for forming a building wall structure comprising an elongated support carrier, means coacting with said carrier defining the locations for, and serving to releasably hold, framing members secured to said carrier for forming portions of said wall structure, means supporting said carrier for movement along a predetermined path, means bounding said path and serving to closely define the span thereof, the last named means engaging said wall structure during movement thereof along said path to positively maintain the width thereof, and means disposed adjacent said framing members moving along said path for interconnecting said framing members during movement of said carrier along said path.
 3. A system for forming a building wall structure comprising an elongated support carrier, means coacting with said carrier defining the locations for, and serving to releasably hold, framing members secured to said carrier for forming portions of said wall structure, means bounding said carrier and engaging said wall structure to positively maintain the span thereof, means adjacent said framing members when moving along said path for interconnecting framing members, and means for operating the last named means in response to relative movement between said carrier and said last-named means. 